Toyota 44610-02210
Brake Booster

Begin by installing the grommet followed by checking the valve assembly after which install a new brake booster gasket on top of the brake booster assembly. The installation process begins by connecting the push rod clevis along with its lock nut to the brake booster assembly. After adjusting the brake pedal height, torque the lock nut correctly. Fasten 4 brake booster assembly nuts to 12.7 Nm while tightening them to 130 kgf-cm before connecting the brake tubes to the clamp with 2 or 3 tubes. Attach the vacuum hose to the brake booster assembly and connect the front brake tube No. 5 with Special Service Tool: 09023-00101 while maintaining correct grommet installation and torquing the tube to 15 Nm (155 kgf-cm, 11 ft-lbf). The front wheel LH needs to be installed with 103 Nm (1,050 kgf-cm, 76 ft-lbf) torque followed by attaching the brake master cylinder push rod clevis. The brake master cylinder sub-assembly installation requires 3 bolts for mounting, after which you should install the air cleaner element. The next step is to mount the air cleaner cap sub-assembly followed by brake fluid addition into the reservoir. The operator should begin bleeding the master cylinder alongside the brake line. Test and modify the brake pedal height and its free play and reserve distance then inspect the reservoir fluid level. The inspection should include a search for brake fluid leaks together with examination of the brake booster assembly.

Begin brake booster assembly installation by inserting the grommet before verifying the valve assembly followed by placing the new brake booster gasket onto the assembly. First install the push rod clevis followed by the lock nut and adjust the brake pedal height before torquing the nut. Fasten the brake booster assembly with 4 nuts which need a torque setting of 12.7 Nm (130 kgf-cm, 9 ft-lbf) before adding 2 or 3 brake tubes to the clamp. Attach the vacuum hose to the brake booster assembly while using Special Service Tool: 09023-00101 to connect front brake tube No. 5 and tighten it to 15 Nm (155 kgf-cm, 11 ft-lbf). Make sure the grommet sits properly at its installed position. Fasten the front wheel LH using a torque of 103 Nm (1,050 kgf-cm, 76 ft-lbf) before joining the brake master cylinder push rod clevis. Start by mounting the air cleaner element followed by securing 3 bolts to join the brake master cylinder sub-assembly with the air cleaner case sub-assembly. After installing the air cleaner cap sub-assembly you need to add brake fluid to its reservoir. Vehicle operators should start the bleeding process by draining fluid from both the brake master cylinder and the brake line. Verify the brake pedal height and free play and reserve distance operations before checking the reservoir fluid level. Conduct an inspection of the brake fluid leak locations as well as the brake booster assembly to make sure everything operates as intended.

Install the push rod clevis and lock nut, adjusting the brake pedal height and torquing the lock nut.

Reinstall the cruise control actuator assy with 2 nuts and bolt, torquing to 43 Nm (438 kgf-cm, 32 ft. lbs.).

Proceed by removing the front wheel LH.

Remove the air cleaner cap sub-assembly and the air cleaner case sub-assembly by taking out the air cleaner element and the 3 bolts.

Install the brake master cylinder push rod clevis, followed by the brake master cylinder sub-assy, and then the air cleaner case sub-assy by securing it with 3 bolts and reinstalling the air cleaner element.

Check and adjust the brake pedal height, free play, reserve distance, and fluid level in the reservoir, while also inspecting for brake fluid leaks and the brake booster assembly.

Take out the brake booster assembly using Special Service Tool: 09023-00101 to disconnect the front brake tube No. 5.

Connect the front brake tube No.5 at a torque of 15 Nm (155 kgf-cm, 11 ft. lbs.), ensuring the grommet is correctly installed.

Remove the air cleaner cap sub-assy and the air cleaner case sub-assy by taking out the air cleaner element and the 3 bolts.